Hybrid shipping pallet system

ABSTRACT

A shipping pallet includes a deck having an upper surface and an opposing lower surface and a plurality of deck support structures, each of the deck support structures having a plurality of prongs protruding from an upper surface thereof. The plurality of prongs of each deck support structure penetrate and engage the lower surface of the deck so as to cause the plurality of deck support structures to be attached to the deck.

RELATED APPLICATIONS

This patent application claims the benefit of, under Title 35, United States Code, Section 119(e), U.S. Provisional Patent Application No. 60/549,842, filed Mar. 3, 2004.

FIELD OF THE INVENTION

The present invention relates to an improved pallet for packaging, material handling, shipping, and the like. More particularly, the present invention relates to a hybrid shipping pallet system that has numerous advantages over currently known wood, plastic and paper pallets.

BACKGROUND OF THE INVENTION

Traditionally, pallets have been made of wood planks nailed together. In one common structure, a series of parallel upper wood planks are nailed to the top of three transversely extending, parallel, and equally-spaced wood support planks. Similarly, a series of parallel lower wood planks are nailed to the bottom of the three support planks. The tines of forklifts and/or pallet jacks can slide under the upper planks in the two parallel channels formed by the three spaced support planks. The forklift or pallet jack can then raise its tines, which lifts the pallet and anything mounted on it. While such pallets have been used for decades, they suffer from a surprising number of deficiencies.

Outbreaks of non-indigenous insect pests (such as the Asian long horn beetle and the pinewood nematode) across continents have been traced in part to wood transport packaging, including wood pallets. Within the past year, it was reported that Asian long horn beetles had invaded and now threatened to destroy the maple tree population of Central Park in New York City. The first organized effort to combat this emerging crisis began when on Oct. 1, 2001, in an effort to stop infestation by the pinewood nematode, the European Union imposed short term “emergency measures” on all coniferous (softwoods, such as pine) solid wood packaging originating in the U.S., Canada, China, and Japan. Strict enforcement was scheduled to begin after Oct. 1, 2002, with severe consequences for non-compliance.

With insect infestations posing a serious and imminent threat to plant and tree health worldwide, these short-term emergency measures have now been superceded by global standards developed by the International Plant Protection Organization (IPPO), a division of the United Nations. In March 2002, representatives from almost ninety nations officially passed these new global standards. These global standards require all solid wood packaging—both hardwood and softwood—to be heat treated at 56° C. for 30 minutes, and stamped to certify compliance. In addition to heat treatment, other treatment methods authorized under the standards include: kiln drying, chemical pressure impregnation, and fumigation. Implementation of these global standards will be left up to each member country. While it is anticipated that it could take 1-2 years to implement the standard, some European nations and Canada had put this standard in place by the end of 2002 because of the spreading pinewood nimetode threat.

These requirements for the treatment of wood pallets have made the use of such wood pallets disadvantageous for many reasons, including increased cost and manufacturing complexity. However, it should be noted that since plastics and paper/corrugated packaging materials are inherently bug-proof, these new regulations apply only to international shipments involving wood packaging materials. Upon inspection for export, any wood pallet found not to be in compliance with the rules would be destroyed, forcing goods to be re-palletized onto an approved pallet, or fumigated on site—all at the expense of the shipper.

Another deficiency of wood pallets relates to environmental concerns. According to the Rainforest Action Network, an environmental group, more than one million forest acres are chopped every year for wood pallets. The very title and by-line of an Article that appeared in the Wall Street Journal in 1998, cogently captures the essence of the environmental concerns about wood pallets: “As Old Pallets Pile Up, Critics Hammer Them As a New Eco-Menace”, “They Can Deliver the Goods, But They Clog Landfills And Gobble Up Trees”. The article reports that one third of US landfills will not take pallets, and others charge fees for taking pallets. Most pallets are eventually abandoned, left to pile up as a dangerous nuisance.

These issues are not of great concern with plastics and paper/corrugated packaging materials, as pallets made of these materials are recyclable. It is worth noting that recyclable paper-based pallets are already favored for export to environmentally concerned countries such as the various EU members.

A further deficiency of wood pallets revolves around the effect of their weight on a whole range of issues, such as added transportation costs, and handling difficulties for workers. The average weight of a 48″×40″ block style wood pallet with four way entry is approximately 45 lbs. The shipper must pay for the net weight of the pallet as part of the total transportation cost of the shipment, in all less-than-truckload (so-called “LTL”) volumes, as well as all domestic and international shipments by air. This added expense is significant. For example, the average domestic LTL trucking rate is $0.33 per lb. This means that it costs the shipper $14.85 to ship each pallet without any freight on it. With domestic air rates ranging from $0.60-$1.50 per lb (depending on the service level), and export air rates at $1.00 per lb., the expense of shipping the pallet itself can have a profound impact on the total transportation cost.

The handling of wood pallets by warehouse workers has been an issue for many years in terms of the repetitive lifting of heavy weights and injuries caused by splinters, exposed nails, and falling pallets. The issue of weight has grown as a concern since women are joining the traditionally male workforce in warehouses and shipping docks. OSHA has pressed U.S. industries to minimize human lifting weights to 45 lbs. It is common knowledge that the weight and condition of wood pallets have contributed to workmen's compensation claims in the transportation industry and has become a cost factor regarding its use. Government regulations and company work rules usually require that a damaged wood pallet be taken out of service and either repaired or replaced unless the damage is very minor.

Still a further deficiency of wood pallets is the quality of the top load-bearing surface. Very frequently, the top surface is made of rough and uneven wood, which can cause damage to outer packaging, and sometimes to the goods themselves. While this might seem minor, in normal warehouse conditions where freight is handled roughly and quickly, damage claims can easily result.

For decades, non-wood alternative pallet products, particularly paper-based/corrugated and plastic products, have been manufactured and widely distributed. Examples of such pallets are disclosed in U.S. Pat. Nos. 5,329,861, 5,595,125, 5,660,118, 5,784,971, 5,934,202, 6357,364, and 6,612,207 Until the current phytosanitary issues became an international crisis, and the regulations to combat infestation became a certainty, these alternative products faced a number of obstacles that limited their ability to gain greater market share against wood pallets. One such obstacle is that generally pallets made from durable, recyclable, and reusable plastics, are regarded as far too expensive for single-use applications, and have only gained market share in closed loop transport systems where they can be recovered. Good plastic pallets generally cost between $75 and $90 each. Another obstacle has been that traditional paper-based pallets made from “homogeneous” materials such as Kraft paper honeycomb and corrugated paperboard have never enjoyed a significant price advantage over new wood pallets, or a cost advantage when compared to used/reconditioned wood pallets.

A further obstacle has been that traditional paper-based pallets generally cannot match many performance attributes inherent to wood pallets (especially relating to the deck support aspect of load-bearing). No currently offered paper pallet even claims to be strong enough to be used in unsupported warehouse racking systems. Wood pallets can be placed side by side in a warehouse rack loaded with freight, and stacked one on top of the other to a reasonable height limit. Such is not true of currently known paper-based pallets.

Still a further obstacle facing paper-based pallets is that they have not been able to overcome their greatest perceived weakness; that they cannot be exposed to any water, or be used in a wet environment. Consequently, unlike wood pallets, paper pallets cannot be stored outside, which is a common practice in many area of this country. Although U.S. Pat. No. 5,359,861 does briefly mention that portions of the paper-based pallet could be coated with polyethylene, this process may not be very effective and typically is high in cost.

What is desired, therefore, is a pallet system which is constructed from a wood alternative, which does not present a hazard of facilitating the migration of pests, which is not subject to the treatment requirements imposed by governmental agencies, which is relatively inexpensive to create and use, which does not pose great environmental concerns, which is lower in weight than wood pallets, which has a top surface which is not prone to damaging goods shipped thereon, which has a strength similar to that of wood pallets, and which is water resistant such that it can be used in humid or wet environments.

SUMMARY OF THE EMBODIMENTS OF THE INVENTION

Accordingly, it is an object of the present invention to provide a pallet system which is constructed from a wood alternative.

Another object of the present invention is to provide a pallet system having the above characteristics and which does not present a hazard of facilitating the migration of pests.

A further object of the present invention is to provide a pallet system having the above characteristics and which is not subject to the treatment requirements imposed by governmental agencies.

Still another object of the present invention is to provide a pallet system having the above characteristics and which is relatively inexpensive to create and use.

Yet another object of the present invention is to provide a pallet system having the above characteristics and which does not pose great environmental concerns.

Still yet another object of the present invention is to provide a pallet system having the above characteristics and which is lower in weight than wood pallets.

Still a further object of the present invention is to provide a pallet system having the above characteristics and which has a top surface which is not prone to damaging goods shipped thereon.

Yet still a further object of the present invention is to provide a pallet system having the above characteristics which has strength similar to that of wood pallets.

Still yet another object of the present invention is to provide a pallet system having the above characteristics and which is water resistant such that it can be used in humid or wet environments.

These and other objects are achieved according to one embodiment of the present invention by provision of a shipping pallet comprising a deck having an upper surface and an opposing lower surface and a plurality of deck support structures, each of the deck support structures having a plurality of prongs protruding from an upper surface thereof. The plurality of prongs of each deck support structure penetrate and engage the lower surface of the deck so as to cause the plurality of deck support structures to be attached to the deck.

In some embodiments, the deck comprises corrugated board having at least one intermediate corrugated member sandwiched between linerboard facings. In certain of these embodiments, the deck comprises triple wall corrugated board having three intermediate corrugated members sandwiched between four linerboard facings. In certain embodiments, the intermediate corrugated members and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant. In certain of these embodiments, the outer linerboard facings are also coated with a waterproof coating, whereby the shipping pallet is waterproof. In other embodiments, the deck comprises a Kraft paper honeycomb panel having a honeycomb core sandwiched between linerboard facings. In certain of these embodiments, the honeycomb core and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant. In certain embodiments, the linerboard facings are coated with a waterproof coating, whereby the shipping pallet is waterproof.

In some embodiments, each of the plurality of deck support structures comprises a unitized extruded or molded part formed from a plastic material. In some embodiments, each of the plurality of deck support structures comprises at least one of structural foam polypropylene and structural foam polyethylene. In some embodiments, each of the plurality of deck support structures is formed from a recycled plastic material. In some embodiments, each of the plurality of deck support structures is formed from a virgin plastic material. In some embodiments, each of the plurality of deck support structures comprises three post sections set between a lower skid and an upper rail. In certain of these embodiments, the plurality of prongs of each deck support structure, protrude from an upper surface of the upper rail.

In some embodiments, each of the plurality of prongs comprises a barb so as to enhance attachment between the plurality of deck support structures and the deck. In certain of these embodiments, the barb is formed in a substantially vertical surface of each of the plurality of prongs. In certain of these embodiments, each of the plurality of prongs further comprises a sloped surface, and the barb is positioned on a side of the prong opposite to the sloped surface. In certain embodiments, the barb is formed in a sloped surface of each of the plurality of prongs.

In some embodiments, each of the plurality of deck support structures is attachable without tools to the deck by forcing each of the plurality of deck support structures and the deck together such that the plurality of prongs of each deck support structure penetrate and engage the lower surface of the deck. In some embodiments, each of the plurality of deck support structures is detachable without tools from the deck by gripping an end of each of the plurality of deck support structures adjacent an end thereof and pulling each of the plurality of deck support structures away from the deck.

In accordance with another embodiment of the present invention, a shipping pallet comprises a deck having an upper surface and an opposing lower surface, the deck comprising corrugated board having at least one intermediate corrugated member sandwiched between linerboard facings. The shipping pallet also comprises a plurality of deck support structures, each of which comprises a unitized extruded or molded part formed from a plastic material, each of the deck support structures having a plurality of prongs protruding from an upper surface thereof. The plurality of prongs of each deck support structure penetrate and engage the lower surface of the deck so as to cause the plurality of deck support structures to be attached to the deck, and each of the plurality of prongs comprises a barb so as to enhance attachment between the plurality of deck support structures and the deck. Each of the plurality of deck support structures is attachable without tools to the deck by forcing each of the plurality of deck support structures and the deck together such that the plurality of prongs of each deck support structure penetrate and engage the lower surface of the deck, and each of the plurality of deck support structures is detachable without tools from the deck by gripping an end of each of the plurality of deck support structures adjacent an end thereof and pulling each of the plurality of deck support structures away from the deck.

In some embodiments, the deck comprises triple wall corrugated board having three intermediate corrugated members sandwiched between four linerboard facings. In some embodiments, the intermediate corrugated members and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant. In certain of these embodiments, the linerboard facings are coated with a waterproof coating, whereby the shipping pallet is waterproof.

In some embodiments, each of the plurality of deck support structures comprises at least one of structural foam polypropylene and structural foam polyethylene. In some embodiments, each of the plurality of deck support structures comprises three post sections set between a lower skid and an upper rail. In certain of these embodiments, the plurality of prongs of each deck support structure, protrude from an upper surface of the upper rail.

In some embodiments, the barb is formed in a substantially vertical surface of each of the plurality of prongs. In certain of these embodiments, each of the plurality of prongs further comprises a sloped surface, and the barb is positioned on a side of the prong opposite to the sloped surface. In some embodiments, the barb is formed in a sloped surface of each of the plurality of prongs.

In accordance with a further embodiment of the present invention, a shipping pallet comprises a deck having an upper surface and an opposing lower surface, the deck comprising triple wall corrugated board having three intermediate corrugated members sandwiched between four linerboard facings. The shipping pallet also comprises a plurality of deck support structures, each of which comprises a unitized extruded or molded part formed from at least one of structural foam polypropylene and structural foam polyethylene, each of the deck support structures comprising three post sections set between a lower skid and an upper rail, and having a plurality of prongs protruding from an upper surface of the upper rail. The plurality of prongs of each deck support structure penetrate and engage the lower surface of the deck so as to cause the plurality of deck support structures to be attached to the deck. Each of the plurality of prongs comprises a barb so as to enhance attachment between the plurality of deck support structures and the deck, the barb being formed in a substantially vertical surface of each of the plurality of prongs, which substantially vertical surface is positioned opposite to a sloped surface of the barb. Each of the plurality of deck support structures is attachable without tools to the deck by forcing each of the plurality of deck support structures and the deck together such that the plurality of prongs of each deck support structure penetrate and engage the lower surface of the deck, and each of the plurality of deck support structures is detachable without tools from the deck by gripping an end of each of the plurality of deck support structures adjacent an end thereof and pulling each of the plurality of deck support structures away from the deck.

In some embodiments, the intermediate corrugated members and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant. In certain of these embodiments, the linerboard facings are coated with a waterproof coating, whereby the shipping pallet is waterproof.

The invention and its particular features and advantages will become more apparent from the following detailed description considered with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing an assembled pallet in accordance with an embodiment of the present invention;

FIG. 2 is a perspective exploded view, partially cut away, showing an unassembled pallet in accordance with an embodiment of the present invention;

FIGS. 3A-3C are, respectively, perspective, side and front views showing portions of an embodiment of the rail portions of the pallets shown in FIGS. 1 and 2;

FIGS. 4A-4C are, respectively, perspective, side and front views showing portions of an embodiment of the rail portions of the pallets shown in FIGS. 1 and 2; and

FIG. 5 is a perspective view showing an embodiment of the rail portions of the pallets shown in FIGS. 1 and 2.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention is directed to a hybrid pallet system having components formed from various materials. The pallet immediately distinguishes itself from known prior art pallets, all of which (whether wood, plastic, or paper-based) are made completely from those homogeneous materials. Referring to FIGS. 1 and 2, the pallet 10 includes three deck support structures 12, each preferably made as a unitized extruded or molded part from a plastic material, either new or recycled, and a deck 14 made from a layered paper material, also either new or recycled, preferably having a corrugated or honeycomb configuration.

Each unitized deck support structure 12 includes three post sections (as pallet feet) 16, set between a skid (which will rest on the ground) 18, and a rail (upon which the pallet deck will be positioned) 20. This unitized I-beam design using strong yet flexible plastic, or plastic composite material, gives the pallet a load-bearing capacity competitive with wood, and superior to that of corrugated or honeycomb pallet feet. The three support structures 12 are designed and configured with openings 22 between post sections 16 to facilitate four-way entry (either by forklift or pallet jack), and enable the pallet 10 to be used on conveyers or roller-systems for maximum versatility.

The support structures 12 can made of, among other things, virgin or recycled “structural foam” polypropylene, polyethylene, or other composite material of recycled plastic, becoming more commonly available. Structural foam injection molding is advantageous because it is a single step process, and can reduce the weight of each support structures 12 by up to approximately 33%, which is very desirable for a shipping pallet. Along with weight reduction, less plastic, whether virgin or recycled (or even a combination of both which can be used), substantially reduces the unit cost of each support structures 12. A multiple cavity mold of the support structures 12 can be designed for use with structural foam presses that are operated by injection molders in North America and various parts of the world, so the part can be produced and distributed at a competitive cost in volume. The rails made from polypropylene and/or polyethylene would be reusable and recyclable.

The support structures 12 are generally uniform, of one “standard size,” and are completely interchangeable. This simplifies the process of shipping the unassembled deck support parts, pallet assembly, distribution, and replacement of broken parts. In terms of the business model, making the support structures 12 uniform and interchangeable creates significant economies of scale to reduce the cost of producing the part, especially as volumes increase. This allows for a pallet constructed in accordance with the present invention to be priced competitively with new wood pallets.

Standardizing the support structures 12 also facilitates another significant operational and marketing feature. It allows for varying size decks 14 to be used without having to change the size of the support structures 12, building even greater versatility into this system for shippers that use multiple size pallets in their business.

The load-bearing top deck 14 may be made from, for example, triple wall corrugated board as is shown in FIG. 1. Triple wall corrugated board, as defined by the Uniform Freight Classification Rules, is a structure formed by four flat facings 24 and three intermediate corrugated members 26. The four flat facings 24 are linerboard. For the two “outer” linerboard facings 24, the paperweight (min/max) is preferably 69190 or 90190 . The preferred paperweights of the two “inner” linerboard facings 24 (min/max) are 42# or 69#. The preferred paperweights for the three intermediate corrugated members 26 are (min/max) 26# or 33190 . The preferred corrugation (wave shape) fluting configuration of the three intermediate corrugated members 26 are either AAA or ACC. A-flute has 33 flutes (plus or minus 3) per linear foot, and an approximate height of 3/16″, and C-flute has 39 flutes per linear foot (plus or minus 3) and an approximate height of 9/64″ (the heights not including the thickness of the linerboard facings 24).

The load-bearing top deck 14 may alternatively be made from fabricated Kraft paper honeycomb panels, which are 100% recyclable, as shown in FIG. 2. Kraft paper honeycomb sandwiched panels (which also derive their strength from an I-beam design), provide the highest strength to weight ratio of any available material. The use of this light-weight material mitigates and offsets the weight of the plastic deck supports 12, while still maintaining the total weight of the pallet 10 significantly less than that of a wood pallet (though somewhat higher than a homogeneous paper-based pallet).

However, as is known in the art, standard triple wall corrugated board and standard Kraft paper honeycomb are not water-proof or resistant to moisture. As with all paper-based pallet solutions, this puts triple wall corrugated board and honeycomb at a disadvantage against waterproof materials, and has served to limit their application to environments with no risk of moisture or water exposure. Applicants have, however, developed and successfully tested moisture resistant and virtually waterproof corrugated paper board, and honeycomb pallet decks. The water resistant deck is comprised of honeycomb core and/or corrugated members and linerboard papers that have been treated internally for water resistance, using a waterproofing chemical treatment or “sizing.” Although any of numerous chemical treatments may be employed, it has been found that chemical compounds designed to make paper non-wicking and water resistant provide acceptable results. Of course, it should be recognized that numerous other chemical treatments may be employed.

The waterproof version of the deck features linerboard facings that have additionally been treated with waterproof coatings to effectuate the highest level of protection. Although any of numerous coatings may be employed, it has been found that coatings designed for water and/or oil repellency provide acceptable results. Of course, it should be recognized that numerous other coatings may be employed.

Each of three versions of the pallet deck is particularly designed to address a separate segment of the market. The untreated standard triple wall corrugated board or honeycomb deck can be offered as a general purpose platform, while the water resistant type can be used in any transit application; for all weather conditions. In many instances the deck itself (which is generally loaded with freight prior to exposure to water or moisture) does not need to be water resistant or waterproof. Regardless of which type of deck is employed, the standardized deck support structures are always able to withstand moisture, rain, or standing water during transit, a major advantage against all of the known paper-based pallet alternatives.

A main purpose for the waterproof version of the pallet deck is to address a very unique and challenging market segment, and to replace wood pallets in a niche market they have always owned—the shipment of fresh and frozen agricultural/produce commodities, meat, and poultry products. These products are loaded in wet conditions, or are subjected to very high moisture or wet conditions as part of the packing or shipping process itself. Such products include fresh asparagus, broccoli, and cherries, as well as fresh/frozen meat, poultry etc. In those type of shipping environments (as well as many others), wood pallets are stored outside of warehouses to save precious space. This is particularly common in the relatively dry regions of the west and southwest.

These are huge markets that all paper-based pallets (as well as plastic pallets which are considered to be far too expensive for single-use) are barred from entering, due to the “water exposure and storage issue.” According to forwarder feedback, if there were a viable non-wood alternative, the industry would choose to move away from wood pallets for these applications, because of all of their well-known disadvantages. The pallet of the present invention, with a waterproof deck and waterproof support structures, is able to meet this challenge. At the very least the un-assembled deck support parts could be stored efficiently in or outside of a warehouse in those areas that follow that custom.

Referring now to FIGS. 3A-5, unlike prior art pallets, no glues, connecting hardware, or tools are required to assemble or disassemble the pallet 10. Instead, the top surface of each support structure 12 is provided with a plurality of prongs 28, 28′, 28″ protruding therefrom, which prongs 28, 28′, 28″ have pointed tips 32 adapted to puncture the lower surface of the top deck 14, and may include a barb or undercut 30 (best seen in FIGS. 3B and 4B) to provide enhanced connection therebetween. The prongs 28, 28′, 28″ allow for the support structures 12 to be quickly and easily attached to and removed from the top deck 14. The prongs 28, 28′, 28″ may be elongated in shape (as shown in FIGS. 5) or may be formed as discrete protuberances (as shown in FIGS. 3A and 4A).

More specifically, with reference particularly to prongs 28, 28′ shown in FIGS. 3A-4C, the length of each prong 28, 28′ is such that it will penetrate the outer facing of the deck 14 and, particularly in the case of the triple wall corrugated board, just reach but not press into the far side of the first flute and its adjacent inner facing. The length is maximized so that its tip and tapered sides facilitate easier penetration of the outer facing. Barb or undercut 30 is cut on the opposite of the sloped side 34 of the prong 28 and extends down to the bottom of the prong's base to catch and latch-up with the outer facing of the deck 14 as it arrives during penetration. Since the puncture will cause the edges of the outer facing to curl upwards towards the top of the prong 28, 28′ during penetration, the barb or undercut 30 is made high enough to catch that curl. The barbed or undercut side of the prong 28 may be vertical whereas its opposite side is sloped (as shown in FIG. 3B), so that as the prong 28 enters the substrate, the slope is forcing or pushing the paper against the notch and locking the paper against it, or the barbed or undercut side of the prong 28′ may also be sloped (as shown in FIG. 4B). The slope of the opposite two sides 36, 36′ are angled and spread wide enough to give the prong sufficient bending strength and thus prevent it from snapping off. The entirety of each of the two opposite sides 36′ may be sloping (as shown in FIG. 4C) or a portion thereof may be vertical (as shown in FIG. 3C). The design of the prongs 28, 28′, 28″ gives the paper enough shearing surface (edge) to keep the deck 14 from sliding on the support structures 12, as when full, pallets are loaded and pushed against one another. The edges of the prongs 28, 28′, 28″ may have a slight radius, as is typically found in an injection molded plastic part, so that the paper tear forces are more effective, although the prong 28, 28′, 28″ will work adequately if the point 32 and edges are sharp. Additional notching can be done on one or more of the opposite sides of the prong 28, 28′, 28″ if desired.

The finished, unassembled pallet decks 14 can be shipped by rail or truck to strategic assembly/distribution locations from plant locations most proximate to the customer. This can be accomplished efficiently and at a relatively low cost, since the decks are relatively flat and pack well into containers, as is the case with the deck supports. This is a major strategic advantage since all wood and non-wood-alternative pallet producers ship their pallets fully assembled from their various plant locations to distributors or customers, which adds significant freight costs for the customer.

The method of attaching the support structures 12 to the paper deck 14 can be done in the field; done by an apprentice; done without the need of any extra materials, parts or bonding agents; done for any configuration of pallet; done quickly; and done with precision, security and quality. The pallet 10 is shipped as two components, the deck 14 and the three support structures 12 (often referred to as rails, feet, pads, legs, etc). Each support structure 12 has a configuration of small prongs 28, 28′, 28″ on the top cross-member 20 that penetrate the deck surface and latch onto the deck's facing. This latch-up is sufficient enough so that the support structures 12 will remain attached with normal handling of a pallet 10. However, it is designed such that with a tug from an end of the support structure 12, it can be unseated and then easily removed for reuse.

Having a pallet deck 14 removable from reusable deck support structures 12 has numerous marketing and operational advantages. At minimal additional cost, a “used” deck 14 can be removed if required and replaced in minutes at the other end of a distribution system, and thus be brought into compliance “again” from the standpoint of regulated industries that require the use of only new pallets (for sanitary reasons). There are many industries that fall into this category such as healthcare and pharmaceuticals. As interchangeable parts, the unassembled deck supports 12 can be less expensively recaptured between locations in a closed loop distribution system. The objective, however, is to keep the cost of those parts low enough that the pallet can still be priced as a one-way pallet. The pallet of the present invention has also been designed to be used in warehouse racking systems.

The present invention, therefore, provides a pallet system which is constructed from a wood alternative, which does not present a hazard of facilitating the migration of pests, which is not subject to the treatment requirements imposed by governmental agencies, which is relatively inexpensive to create and use, which does not pose great environmental concerns, which is lower in weight than wood pallets, which has a top surface which is not prone to damaging goods shipped thereon, which has a strength similar to that of wood pallets, and which is water resistant such that it can be used in humid or wet environments.

Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art. 

1. A shipping pallet comprising: a deck having an upper surface and an opposing lower surface; a plurality of deck support structures, each of said deck support structures having a plurality of prongs protruding from an upper surface thereof; and wherein the plurality of prongs of each deck support structure penetrate and engage the lower surface of said deck so as to cause the plurality of deck support structures to be attached to said deck.
 2. The shipping pallet of claim 1 wherein said deck comprises corrugated board having at least one intermediate corrugated member sandwiched between linerboard facings.
 3. The shipping pallet of claim 2 wherein said deck comprises triple wall corrugated board having three intermediate corrugated members sandwiched between four linerboard facings.
 4. The shipping pallet of claim 2 wherein the intermediate corrugated members and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant.
 5. The shipping pallet of claim 4 wherein the linerboard facings are coated with a waterproof coating, whereby the shipping pallet is waterproof.
 6. The shipping pallet of claim 1 wherein said deck comprises a Kraft paper honeycomb panel having a honeycomb core sandwiched between linerboard facings.
 7. The shipping pallet of claim 6 wherein the honeycomb core and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant.
 8. The shipping pallet of claim 7 wherein the linerboard facings are coated with a waterproof coating, whereby the shipping pallet is waterproof.
 9. The shipping pallet of claim 1 wherein each of said plurality of deck support structures comprises a unitized extruded or molded part formed from a plastic material.
 10. The shipping pallet of claim 1 wherein each of said plurality of deck support structures comprises at least one of structural foam polypropylene and structural foam polyethylene.
 11. The shipping pallet of claim 1 wherein each of said plurality of deck support structures is formed from a recycled plastic material.
 12. The shipping pallet of claim 1 wherein each of said plurality of deck support structures is formed from a virgin plastic material.
 13. The shipping pallet of claim 1 wherein each of said plurality of deck support structures comprises three post sections set between a lower skid and an upper rail.
 14. The shipping pallet of claim 13 wherein the plurality of prongs of each deck support structure, protrude from an upper surface of the upper rail.
 15. The shipping pallet of claim 1 wherein each of the plurality of prongs comprises a barb so as to enhance attachment between said plurality of deck support structures and said deck.
 16. The shipping pallet of claim 15 wherein the barb is formed in a substantially vertical surface of each of the plurality of prongs.
 17. The shipping pallet of claim 16 wherein each of the plurality of prongs further comprises a sloped surface, and wherein the barb is positioned on a side of the prong opposite to the sloped surface.
 18. The shipping pallet of claim 15 wherein the barb is formed in a sloped surface of each of the plurality of prongs.
 19. The shipping pallet of claim 1 wherein each of said plurality of deck support structures is attachable without tools to said deck by forcing each of said plurality of deck support structures and said deck together such that the plurality of prongs of each deck support structure penetrate and engage the lower surface of said deck.
 20. The shipping pallet of claim 1 wherein each of said plurality of deck support structures is detachable without tools from said deck by gripping an end of each of said plurality of deck support structures adjacent an end thereof and pulling each of said plurality of deck support structures away from said deck.
 21. A shipping pallet comprising: a deck having an upper surface and an opposing lower surface, said deck comprising corrugated board having at least one intermediate corrugated member sandwiched between linerboard facings; a plurality of deck support structures, each of which comprises a unitized extruded or molded part formed from a plastic material, each of said deck support structures having a plurality of prongs protruding from an upper surface thereof; wherein the plurality of prongs of each deck support structure penetrate and engage the lower surface of said deck so as to cause the plurality of deck support structures to be attached to said deck; wherein each of the plurality of prongs comprises a barb so as to enhance attachment between said plurality of deck support structures and said deck; wherein each of said plurality of deck support structures is attachable without tools to said deck by forcing each of said plurality of deck support structures and said deck together such that the plurality of prongs of each deck support structure penetrate and engage the lower surface of said deck; and wherein each of said plurality of deck support structures is detachable without tools from said deck by gripping an end of each of said plurality of deck support structures adjacent an end thereof and pulling each of said plurality of deck support structures away from said deck.
 22. The shipping pallet of claim 21 wherein said deck comprises triple wall corrugated board having three intermediate corrugated members sandwiched between four linerboard facings.
 23. The shipping pallet of claim 21 wherein the at least one intermediate corrugated member and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant.
 24. The shipping pallet of claim 23 wherein the linerboard facings are coated with a waterproof coating, whereby the shipping pallet is waterproof.
 25. The shipping pallet of claim 21 wherein each of said plurality of deck support structures comprises at least one of structural foam polypropylene and structural foam polyethylene.
 26. The shipping pallet of claim 21 wherein each of said plurality of deck support structures comprises three post sections set between a lower skid and an upper rail.
 27. The shipping pallet of claim 26 wherein the plurality of prongs of each deck support structure protrude from an upper surface of the upper rail.
 28. The shipping pallet of claim 21 wherein the barb is formed in a substantially vertical surface of each of the plurality of prongs.
 29. The shipping pallet of claim 28 wherein each of the plurality of prongs further comprises a sloped surface, and wherein the barb is positioned on a side of the prong opposite to the sloped surface.
 30. The shipping pallet of claim 21 wherein the barb is formed in a sloped surface of each of the plurality of prongs.
 31. A shipping pallet comprising: a deck having an upper surface and an opposing lower surface, said deck comprising triple wall corrugated board having three intermediate corrugated members sandwiched between four linerboard facings; a plurality of deck support structures, each of which comprises a unitized extruded or molded part formed from at least one of structural foam polypropylene and structural foam polyethylene, each of said deck support structures comprising three post sections set between a lower skid and an upper rail, and having a plurality of prongs protruding from an upper surface of the upper rail; wherein the plurality of prongs of each deck support structure penetrate and engage the lower surface of said deck so as to cause the plurality of deck support structures to be attached to said deck; wherein each of the plurality of prongs comprises a barb so as to enhance attachment between said plurality of deck support structures and said deck, the barb being formed in a substantially vertical surface of each of the plurality of prongs, which substantially vertical surface is positioned opposite to a sloped surface of the barb; wherein each of said plurality of deck support structures is attachable without tools to said deck by forcing each of said plurality of deck support structures and said deck together such that the plurality of prongs of each deck support structure penetrate and engage the lower surface of said deck; and wherein each of said plurality of deck support structures is detachable without tools from said deck by gripping an end of each of said plurality of deck support structures adjacent an end thereof and pulling each of said plurality of deck support structures away from said deck.
 32. The shipping pallet of claim 31 wherein the intermediate corrugated members and the linerboard facings are treated internally for water resistance using a waterproofing chemical treatment or sizing, whereby the shipping pallet is water resistant.
 33. The shipping pallet of claim 32 wherein the linerboard facings are coated with a waterproof coating, whereby the shipping pallet is waterproof. 